US2006122309A1PendingUtilityA1

Intercalated layered silicate

46
Individually held — no corporate assignee on recordPriority: Dec 2, 2004Filed: Dec 2, 2004Published: Jun 8, 2006
Est. expiryDec 2, 2024(expired)· nominal 20-yr term from priority
Inventors:Michael D. GrahMichael L. BecraftDrew V. SpeerGary W. BeallJeremy Wayne Bartels
C08K 5/103C08K 5/175Y10T428/265C01B 33/44C08K 3/34C08K 5/06C08K 9/04
46
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Claims

Abstract

An intercalated layered silicate comprises a layered silicate and an intercalating agent sorbed between the silicate layers of the layered silicate. The amount of intercalating agent is effective to provide an average interlayer spacing between the silicate layers of at least about 20 Å. The intercalating agent has a formula selected from formulas I through VII described herein. The intercalated layered silicate may be exfoliated by mixing it with a matrix medium and adding sufficient energy to form a dispersed-particle composition. A packaging film, such as a food packaging film, may comprise the dispersed-particle composition.

Claims

exact text as granted — not AI-modified
1 . An intercalated layered silicate comprising: 
 a layered silicate comprising a plurality of silicate layers; and    an intercalating agent sorbed between the silicate layers in an amount effective to provide an average interlayer spacing between the silicate layers of at least about 20 Å, wherein the intercalating agent has a formula selected from:                          wherein:    R 4  represents any of:    1) an acyl group having at least 8 carbon atoms;    2) an alkyl group having at least 8 carbon atoms;    3) an alkenyl group having at least 8 carbon atoms;    4) an alkadienyl group having at least 8 carbon atoms; and    5) a carbon chain group having at least 8 carbon atoms, wherein the carbon chain group incorporates one or more pendant or terminal groups selected from hydroxyl, carboxyl, epoxy, isocyanate, aryl, and arylmethyl, wherein the arylmethyl group has the formula                          wherein “Ar” represents an aryl group, and R 6  and R 7  independently represent hydrogen, an acyl group, an alkyl group, or an alkenyl group;    R 5 represents H, —CH 3 , —CH 2 CH 3 , or any of the groups represented by R 4 ;    R 8  represents an oxylated group having a formula selected from:                          wherein “n” ranges from 2 to 12 and “x” ranges from 4 to 14; and    R 1 , R 2 , and R 3  each independently represents H, —CH 3 , —CH 2 CH 3 ,                          or any of the groups represented by R 4  and R 8 , provided that at least two R 1 , R 2 , and R 3  is H.    
   
   
       2 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula I.  
   
   
       3 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula II.  
   
   
       4 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula II.  
   
   
       5 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula IV.  
   
   
       6 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula V.  
   
   
       7 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula V and R 8  represents an oxylated group having a formula selected from:  
     
       
         
         
             
             
         
       
     
   
   
       8 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula VI.  
   
   
       9 . The intercalated layered silicate of  claim 1  wherein the intercalating agent has the formula VII.  
   
   
       10 . The intercalated layered silicate of  claim 1  wherein R 4  is branched.  
   
   
       11 . The intercalated layered silicate of  claim 1  wherein R 4  is unbranched.  
   
   
       12 . The intercalated layered silicate of  claim 1  wherein R 4  is an acyl group.  
   
   
       13 . The intercalated layered silicate of  claim 1  wherein R 4  is an alkyl group.  
   
   
       14 . The intercalated layered silicate of  claim 1  wherein each of R 1 , R 2 , and R 3  is a hydrogen.  
   
   
       15 . The intercalated layered silicate of  claim 1  wherein the intercalating agent comprises an ester of pentaerythritol.  
   
   
       16 . The intercalated layered silicate of  claim 1  wherein the intercalating agent comprises a fatty acid ester of pentaerythritol.  
   
   
       17 . The intercalated layered silicate of  claim 1  wherein the intercalating agent comprises pentaerythritol monostearate.  
   
   
       18 . The intercalated layered silicate of  claim 1  wherein the intercalating agent comprises an ester of citric acid.  
   
   
       19 . The intercalated layered silicate of  claim 1  wherein the intercalating agent comprises a fatty acid ester of citric acid.  
   
   
       20 . The intercalated layered silicate of  claim 1  wherein the intercalating agent comprises stearyl citrate.  
   
   
       21 . The intercalated layered silicate of  claim 1  wherein the intercalated layered silicate is essentially free of an intercalating agent comprising an ammonium compound.  
   
   
       22 . The intercalated layered silicate of  claim 1  wherein the intercalated layered silicate is essentially free of an intercalating agent comprising onium functionality.  
   
   
       23 . The intercalated layered silicate of  claim 1  wherein the amount of sorbed intercalating agent is at least about 5 weight parts per 100 weight parts layered silicate.  
   
   
       24 . The intercalated layered silicate of  claim 1  wherein the average interlayer spacing between the silicate layers is at least about 30 Å.  
   
   
       25 . The intercalated layered silicate of  claim 1  wherein the layered silicate is a bentonite clay.  
   
   
       26 . The intercalated layered silicate of  claim 1  having a peak degradation temperature of at least about 360° C.  
   
   
       27 . A method of exfoliating a layered silicate comprising: 
 mixing from about 0.1 to about 100 weight parts of the intercalated layered silicate of  claim 1  with 100 weight parts of a matrix medium to form a mixture; and    adding sufficient energy to the mixture to form a dispersed-particle composition comprising at least about 0.1 weight parts exfoliated particles per 100 weight parts matrix medium.    
   
   
       28 . The method of  claim 27  wherein the exfoliated particles have an average dimension in the shortest dimension of at most about 100 nm.  
   
   
       29 . The method of  claim 27  wherein the matrix medium comprises one or more polymers selected from polyolefin, ethylene/vinyl alcohol copolymer, ionomer, vinyl plastic, polyamide, polyester, and polystyrene.  
   
   
       30 . The method of  claim 27  wherein the matrix medium comprises one or more energy curable polymer precursors.  
   
   
       31 . The method of  claim 27  wherein the matrix medium comprises one or more materials selected from coating solvents, coating binders, and coating resins.  
   
   
       32 . The method of  claim 27  wherein the matrix medium comprises one or more materials selected from ink solvents and ink resins.  
   
   
       33 . The method of  claim 27  wherein the matrix medium comprises one or more materials selected from grease lubricating oils and grease gelling agents.  
   
   
       34 . The method of  claim 27  wherein the matrix medium comprises one or more materials selected from cosmetic lipids, cosmetic emollients, cosmetic humectants, cosmetic film formers, cosmetic binders, cosmetic surfactants, and cosmetic solvents.  
   
   
       35 . The method of  claim 27  wherein the matrix medium comprises one or more pharmaceutical excipients.  
   
   
       36 . The method of  claim 27  wherein the matrix medium comprises an emulsion selected from an oil-in-water emulsion and a water-in-oil emulsion.  
   
   
       37 . The method of  claim 27  comprising mixing from about 1 to about 10 weight parts of the intercalated layered silicate of  claim 1  with 100 weight parts of a matrix medium.  
   
   
       38 . The method of  claim 27  comprising adding sufficient energy to the mixture to form a dispersed-particle composition comprising at least about 1 weight parts exfoliated particles per 100 weight parts matrix medium.  
   
   
       39 . A dispersed-particle composition comprising: 
 at least about 50 weight % of a matrix medium; and    from at least about 0.1 to at most about 50 weight % of particles dispersed in the matrix medium, the particles having an average size in the shortest dimension of at most about 100 nm, the particles comprising:    silicate platelets; and    an intercalating agent sorbed to the silicate platelets, the intercalating agent having a formula selected from formulas I through VII of  claim 1 .    
   
   
       40 . The dispersed-particle composition of  claim 39  wherein the matrix medium comprises one or more polymers selected from polyolefin, ethylene/vinyl alcohol copolymer, ionomer, vinyl plastic, polyamide, polyester, and polystyrene.  
   
   
       41 . A packaged food comprising: 
 a package comprising the dispersed-particle composition of  claim 39;  and    a food enclosed in the package.    
   
   
       42 . A packaging film comprising the dispersed-particle composition of  claim 39 , wherein the matrix medium comprises one or more polymers, wherein the one or more polymers are thermoplastic.  
   
   
       43 . A method of packaging a food comprising: 
 enclosing a food in a package comprising the packaging film of  claim 42.

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